Cubic boron nitride compact

ABSTRACT

A CBN compact which contains CBN and a matrix phase, wherein the CBN grain size volume frequency distribution has a distribution spread expressed as d90-d10 of 1 micron or greater, and the d90 maximum value is 5 micron or less.

BACKGROUND OF THE INVENTION

This invention relates to a composition for use in the manufacture ofcubic boron nitride abrasive compacts, and specifically to compacts withenhanced wear resistance, and increased chip resistance.

Boron nitride exists typically in three crystalline forms, namely cubicboron nitride (CBN), hexagonal boron nitride (hBN) and wurtzitic cubicboron nitride (wBN). Cubic boron nitride is a hard zinc blende form ofboron nitride that has a similar structure to that of diamond. In theCBN structure, the bonds that form between the atoms are strong, mainlycovalent tetrahedral bonds. Methods for preparing CBN are well known inthe art. One such method is subjecting hBN to very high pressures andtemperatures, in the presence of a specific catalytic additive material,which may include the alkali metals, alkaline earth metals, lead, tinand nitrides of these metals. When the temperature and pressure aredecreased, CBN may be recovered.

CBN has wide commercial application in machining tools and the like. Itmay be used as an abrasive particle in grinding wheels, cutting toolsand the like or bonded to a tool body to form a tool insert usingconventional electroplating techniques.

CBN may also be used in bonded form as a CBN compact. CBN compacts tendto have good abrasive wear, are thermally stable, have a high thermalconductivity, good impact resistance and have a low coefficient offriction when in contact with iron containing metals.

Diamond is the only known material that is harder than CBN. However, asdiamond tends to react with certain materials such as iron, it cannot beused when working with iron containing metals and therefore use of CBNin these instances is preferable.

CBN compacts comprise sintered masses of CBN particles. When the CBNcontent exceeds 80 percent by volume of the compact, there is aconsiderable amount of CBN-to-CBN contact and bonding. When the CBNcontent is lower, e.g. in the region of 40 to 60 percent by volume ofthe compact, then the extent of direct CBN-to-CBN contact and bonding isless. CBN compacts will generally also contain a binder phase forexample aluminium, silicon, cobalt, nickel, and -titanium.

When the CBN content of the compact is less than 70 percent by volumethere is generally present another hard phase, a secondary phase, whichmay be ceramic in nature. Examples of suitable ceramic hard phases arecarbides, nitrides, borides and carbonitrides of a Group 4, 5 or 6transition metal (according to the new IUPAC format), aluminium oxide,and carbides such as tungsten carbide and mixtures thereof. The matrixconstitutes all the ingredients in the composition excluding CBN.

CBN compacts may be bonded directly to a tool body in the formation of atool insert or tool. However, for many applications it is preferablethat the compact is bonded to a substrate/support material, forming asupported compact structure, and then the supported compact structure isbonded to a tool body. The substrate/support material is typically acemented metal carbide that is bonded together with a binder such ascobalt, nickel, iron or a mixture or alloy thereof. The metal carbideparticles may comprise tungsten, titanium or tantalum carbide particlesor a mixture thereof.

A known method for manufacturing the CBN compacts and supported compactstructures involves subjecting an unsintered mass of CBN particles, tohigh temperature and high pressure conditions, i.e. conditions at whichthe CBN is crystallographically stable, for a suitable time period. Abinder phase may be used to enhance the bonding of the particles.Typical conditions of high temperature and pressure (HTHP) which areused are temperatures in the region of 1100° C. or higher and pressuresof the order of 2 GPa or higher. The time period for maintaining theseconditions is typically about 3 to 120 minutes.

The sintered CBN compact, with or without substrate, is often cut intothe desired size and/or shape of the particular cutting or drilling toolto be used and then mounted on to a tool body utilising brazingtechniques.

CBN compacts are employed widely in the manufacture of cutting tools forfinish machining of hardened steels, such as case hardened steels,ball-bearing steels and through hardened engineering steels. In additionto the conditions of use, such as cutting speed, feed and depth of cut,the performance of the CBN tool is generally known to be dependent onthe geometry of the workpiece and in particular, whether the tool isconstantly engaged in the workpiece for prolonged periods of time, knownin the field as “continuous cutting”, or whether the tool engages theworkpiece in an intermittent manner, generally known in the field as“interrupted cutting”.

Depending on the workpiece geometry, it is common for the CBN tool toexperience both continuous and interrupted cutting within a processcycle and furthermore, the ratio of continuous to interrupted cuttingvaries widely in the field. After extensive research in this field itwas discovered that these different modes of cutting place verydifferent demands on the CBN material comprising the cutting edge of thetool. The main problem is that the tools tend to fail catastrophicallyby fracturing or chipping, exacerbated by an increasing demand in themarket for higher productivity through increased cutting speeds andtherefore the tool has a limited tool life.

U.S. Pat. No. 6,316,094 discloses a CBN sintered body in which CBNparticles of a single average particle size are bonded through a bondingphase. A powdered composition is sintered to produce the sintered body.This powdered composition is made using various mixing methods such asultrasonic mixing and attrition milling. Attrition milling is shown tobe the poorest mixing method.

U.S. Pat. No. 4,334,928 discloses a boron nitride sintered compactcomprising CBN particles and various titanium containing compounds. Thetitanium containing compounds are typically pre-reacted and formed intoa sintered compact which is then crushed. The CBN compact furthercontains CBN having a single average particle size. Relatively lowtemperatures are used in the sintering process to produce the CBNcompact.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided acomposition for use in producing a CBN compact comprising:

-   -   about 45 to about 75 volume % CBN, typically 45 to 70 volume %,        where the CBN is comprised of particles of more than one average        particle size;    -   a secondary hard phase including a compound containing nitride,        carbonitride or carbide of a Group 4, 5 or 6 transition metal or        a solid solution or a mixture thereof; and    -   a binder phase;        where typically the binder phase is present in an amount of        about 5 to 30 weight % of the secondary hard phase.

The volume of CBN present in the composition is preferably from 50 to65%. The average particle size of the CBN is usually less than 10 μm andpreferably less than 5 μm.

The CBN is preferably bimodal, i.e. it consists of particles with twoaverage sizes. The range of the average particle size of the finerparticles is usually from about 0.1 to about 2 μm and the range of theaverage particle size of the coarser particles is usually from about 0.3to about 5 μm. The ratio of the content of the coarser CBN particles tothe finer particles is typically from 50:50 to 90:10.

The composition of the invention contains CBN, a secondary hard phaseand binder phase and may also contain other incidental impurities,including oxide phases, in minor amounts. Tungsten carbide, which actsas a grain growth inhibitor, may be present particularly when thecomposition is milled with tungsten carbide balls. The tungsten carbide,when present, typically does not exceed 3% by volume.

The metal of the nitride, carbonitride or carbide is a Group 4, 5 or 6transition metal, preferably titanium.

The binder phase will preferably consist of aluminium and optionally oneor more of other elements, chosen from silicon, iron, nickel, cobalt,titanium, tungsten, niobium and molybdenum, which may be alloyed,compounded or formed in solid solution with the aluminium. Other binderphases may, however, be used.

The secondary hard phase may be substoichiometric. In this event it maybe pre-reacted with the binder phase e.g. aluminium. This will lead to areaction product of the stoichiometric secondary hard phase andtransition metal aluminides and any unreacted binder phase.

The composition described above is preferably produced by a method whichinvolves optimised powder processing such as attrition milling and inparticular two stage attrition milling; first stage milling forbreakdown of secondary hard phase particles and binder phase, andsubsequently, second stage attrition milling for homogeneous mixing ofCBN and the other matrix materials. Thereafter the composition may besubjected to heat treatment to minimise contaminants in the composition.

According to a second aspect of the invention, a method of producing aCBN compact includes subjecting a composition as described above toconditions of elevated temperature and pressure suitable to produce aCBN compact. Such conditions are those at which CBN iscrystallographically stable and are known in the art.

The composition may be placed on a surface of a substrate, prior to theapplication of the elevated temperature and pressure conditions. Thesubstrate will generally be a cemented metal carbide substrate.

According to another aspect of the invention, there is provided a CBNcompact which comprises CBN and a matrix phase, wherein the CBN grainsize volume frequency distribution has a distribution spread expressedas d90-d10 of 1 micron or greater, and the d90 maximum value is 5 micronor less, preferably 3.5 micron or less, more preferably 2.5 micron orless.

The matrix phase will preferably contain a secondary hard phase and abinder phase, as described above, together with any reaction productsbetween the secondary hard phase, the binder phase and the CBN.

The binder phase is typically present in an amount of about 5 to 30weight % of the secondary hard phase in the matrix.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention concerns the manufacturing of CBN abrasivecompacts. The composition or starting material used in producing the CBNcompact comprises CBN, which consists of particles of more than oneaverage particle size, a secondary hard phase which will include a Group4, 5 or 6 compound; containing nitride, carbonitride or carbide, or amixture or solid solution thereof and a binder phase. The secondary hardphase will typically consist of a Group 4, 5 or 6 compound; containingnitride, carbonitride or carbide, or a mixture or solid solutionthereof. The composition may contain other minor components such asaluminium oxide or tungsten carbide and other incidental impurities suchas Nb, Ta or Mo. Tungsten carbide, which acts as a grain growthinhibitor, may be present particularly when the composition is milledwith tungsten carbide balls. The tungsten carbide, when present,typically does not exceed 3% by volume.

The CBN will contain multimodal particles i.e. at least two types of CBNparticles that differ from each other in their average particle size.“Average particle size” means the major amount of the particles will beclose to the specified size although there will be a limited number ofparticles further from the specified size. The peak in distribution ofthe particles will have a specified size. Thus, for example if theaverage particle size is 2 μm, there will by definition be someparticles which are larger than 2 μm, but the major amount of theparticles will be at approximately 2 μm in size and the peak in thedistribution of the particles will be near 2 μm.

The use of multimodal, preferably bimodal, CBN in the compositionensures that the matrix is finely divided to reduce the likelihood offlaws of critical size being present in the pre-sintered composition.This is beneficial for both toughness and strength in the compactproduced from the composition. Obtaining a matrix material of smallparticle size, typically 0.5 μm, is achieved through mechanical meansduring pre-processing, specifically by attrition milling of thesecondary hard phase, aluminium, any other binder metal and incidentalimpurities.

Milling in general as a means of comminution and dispersion is wellknown in the art. Commonly used milling techniques used in grinding ofceramic powders include conventional ball mills and tumbling ball mills,planetary ball mills and attrition ball mills and agitated or stirredball mills.

In conventional ball milling the energy input is determined by the sizeand density of the milling media, the diameter of the milling pot andthe speed of rotation. As the method requires that the balls tumble,rotational speeds, and therefore energy are limited. Conventional ballmilling is well suited to milling of powders of low to medium particlestrength. Typically, conventional ball milling is used where powders areto be milled to a final size of around 1 micron or more.

In planetary ball milling, the planetary motion of the milling potsallows accelerations of up to 20 times of gravitational acceleration,which, where dense media are used, allows for substantially more energyin milling compared to conventional ball milling. This technique is wellsuited to comminution in particles of moderate strength, with finalparticle sizes of around 1 micron.

Attrition mills consist of an enclosed grinding chamber with an agitatorthat rotates at high speeds in either a vertical or horizontalconfiguration. Milling media used are typically in the size range 0.2 to15 mm and, where comminution is the main objective, milling mediatypically are cemented carbides, with high density. The high rotationalspeeds of the agitator, coupled with high density, small diameter media,provide for extremely high energy. Furthermore, the high energy inattrition milling results in high shear in the slurry, which providesfor very successful co-dispersion, or blending of powders. Attritionmilling achieves finer particles and better homogeneity than the othermethods mentioned.

The finer secondary hard phase and binder phase grains have highspecific surface area and therefore reactivity, leading to very goodsintering between the CBN and secondary hard phase particles. Likewisethe small size of the secondary hard phase particles gives them highspecific surface area, and hence good binding between secondary hardphase particles as well. This high specific surface area effect impartshigh strength to the final structure, without sacrificing the necessarytoughness.

The very fine CBN particles in the typically bimodal distributionprovide the further benefit of inhibiting grain growth of matrixmaterial, apparently by pinning grain boundaries during sintering at theelevated temperature and pressure conditions as described above.

The use of the attrition milling, particularly two step attritionmilling, to achieve the required particle sizes in the pre-sinteredcomposition, along with heat treatment for several hours in a vacuumfurnace, substantially reduces contaminants in the pre-sintered compact.

Typical conditions of elevated temperature and pressure necessary toproduce CBN compacts are well known in the art. These conditions arepressures in the range of about 2 to about 6 GPa and temperatures in therange of about 1100° C. to about 2000° C. Conditions found favourablefor the present invention fall within about 4 to about 6 GPa and about1200 to about 1600° C.

The use of multimodal CBN has been found to produce a CBN compact whichhas excellent toughness and high strength. This compact forms anotheraspect of the invention and has a CBN grain size volume frequencydistribution where the distribution spread expressed as d90-d10 of 1micron or greater, and the d90 maximum value is 5 micron or less,preferably 3.5 micron or less, more preferably 2.5 micron or less.

The CBN compact also has a matrix phase which may contain a secondaryhard phase which will include a compound containing nitride,carbonitride or carbide of a Group 4, 5 or 6 transition metal or a solidsolution or a mixture thereof, for example titanium carbonitride. Thematrix may further comprise a binder phase which consists of aluminiumand optionally one or more of other elements, chosen from silicon, iron,nickel, cobalt, titanium, tungsten, niobium and molybdenum, which isalloyed, compounded or formed in solid solution with the aluminium. Thebinder phase is typically present in an amount of about 5 to 30 weight %of the secondary hard phase in the matrix. During manufacture of thecompact there will be some reaction between the various components, i.e.the CBN, the secondary hard phase and the binder phase. The matrix willalso contain some of these reaction products.

d10 represents the grain size under which 10 percent of the measuredgrains (by volume) will lie. Similarly, d90 represents the grain sizeunder which 90 percent (by volume) of the measured grains will lie. Thespread is therefore defined as the grain size range where 80 percent byvolume of analysed grain sizes fall i.e. the difference between the d90and d10 values (i.e. d90-d10). CBN grains that are finer than the d10value and coarser than the d90 value may be atypical of the distributioni.e. be outliers. Hence the distribution spread is selected as thatgrain size range that falls between the d10 and d90 values for a givenCBN compact.

In order to obtain the d10, d90 and d90-d10 values, a sample piece iscut by using wire EDM and polished. The polished surface of the CBNcompact is analysed using Scanning Electron Microscope. Back-scatterelectron images at a suitable magnifications, 3000, 5000 and 7000 timesmagnifications are selected depending on the average estimated CBN grainsize. If the average grain size is less than one micron, 7000 timesmagnification is used; if the average grain size is greater than 1micron and less than 2 microns, 5000 times magnification is used. If theaverage grain size is greater than 2 micron and less than 3 micron, 3000times magnification is used. At least 30 images are used for theanalysis in order to statistically represent the sample.

The collected grey scale images are analysed in steps. First, grey scaleimage are electronically processed to identify CBN grains in themicrostructure. Then, the identified CBN grains are further separated,and finally, individual grain area is measured and converted to anequivalent circle diameter (ECD). Typically, 10 000 CBN grain sizemeasurements are done on a given material.

The equivalent circle diameter measurement data is further converted toequivalent sphere volume. The percent cumulative volume distributioncurve with 0.1 micron size binding is then obtained using conventionalstatistical processing of the data. The corresponding grain size for d10and d90 values are obtained by drawing straight lines from 10 and 90volume percentages on the y-axis and reading the corresponding grainsize off the x-axis of the cumulative volume distribution curve.

Compacts produced from the composition of the invention and as describedabove have particular application in continuous and light-interruptedand medium to heavy interrupted machining of hardened steels such ascase-hardened and ball-bearing steels.

The invention will now be described, by way of example only, withreference to the following non-limiting examples.

EXAMPLES Example 1

A sub-stoichiometric titanium carbonitride powder(Ti(C_(0.3)N_(0.7))_(0.8) of average particle size of 1.4 micron wasmixed with Al powder, average particle size of 5 micron, using tubularmixer. The mass ratio between Ti(C_(0.3)N_(0.7))_(0.8) and Al was 90:10.The powder mixture was pressed into a titanium cup to form a greencompact and heated to 1025° C. under vacuum for 30 minutes and thencrushed and pulverized. The powder mixture was then attrition milled for4 hours. A CBN powder mixture, containing about 30 wt % CBN with averageparticle size of 0.7 micron and remaining CBN with average particle sizeof 2 micron, was added into the slurry at a certain amount to obtainoverall 60 volume percent CBN. The CBN containing slurry was milled andmixed for an hour using attrition milling. The slurry was dried undervacuum and formed into a green compact and was sintered at 55 kbar (5.5GPa) and about 1300° C. to produce a CBN compact.

Comparative Example 1 Material 1A:

A sub-stoichiometric titanium carbonitride powder,(Ti(C_(0.3)N_(0.7))_(0.8) of average particle size of 1.4 micron wasmixed with Al powder, average particle size of 5 micron, using tubularmixer. The mass ratio between Ti(C_(0.3)N_(0.7))_(0.8) and Al was 90:10.The powder mixture was pressed into a titanium cup to form a greencompact and heated to 1025° C. under vacuum for 30 minutes and thencrushed and pulverized. The powder mixture was then attrition milled for4 hours and 0.7 micron average particle size of CBN was added andattrition milled in hexane for an hour. The amount of CBN was added insuch a way that the total volume percentage of calculated CBN in themixture was about 60 percent. The slurry was dried under vacuum andformed into a green compact and was sintered at 55 kbar (5.5 GPa) andabout 1300° C. to produce a CBN compact.

This compact and the compact produced in Example 1 (referred tohereinafter as Material 1B) were analysed and compared in a machiningtest.

A sample piece from each material was cut by using wire EDM andpolished. The polished surface of the CBN compact was analysed usingScanning Electron Microscope. Back-scatter electron images at 5000 and7000 times magnifications, Material 1B and Material 1A, respectively,were taken and at least 30 images were analysed using image analyses asdescribed previously. The results are summarised in Table 1. Material 1Bhad a significantly broader CBN grain size range (having a distributionspread of 1.388 micron) than Material 1A.

TABLE 1 Summary of CBN grain size analysis results Material 1A Material1B d10 0.296 0.832 d90 0.875 2.22 Distribution spread 0.579 1.388 (d90 −d10)

The sintered compacts were both cut using wire EDM and ground to formcutting inserts. SAE 8620 case hardened steel of 60HRC was continuouslymachined using cutting speeds of 150 m/min with a feed rate of 0.1mm/rev and depth of cut of 0.2 mm.

The cutting test was continued until the cutting edge failed by edgefracture or edge chipping and total cutting distance was measured as anindication of cutting tool performance. None of the tested tools failedas a result of excessive flank wear.

Material 1A and Material 1B cutting performances were evaluated usingthe machining test as described above at a cutting speed of 150 m/min.The performance of Material 1A was 4872 m on average as cuttingdistance, whereas Material 1B surprisingly had on average a cuttingdistance of 6615 m. The achieved improvement with Material 1Bcorresponds to about 36% in relation to Material 1A. Material 1Btherefore significantly improved tool life in continuous cutting ofhardened steel by improving chipping or fracture resistance of thecutting tool.

A second machining test was performed using cutting tool insertsprepared from Material 1A and Material 1B according to ISO standardgeometry, SNMN090308 S0220. The workpiece was selected as ball bearingsteel of SAE 100Cr6 in the form of a tube of 40 mm outside diameter and18.3 mm inside diameter. The ‘test’ section of the workpiece was 50 mmin length. Two square grooves (10 mm by 15 mm in cross-section) wereground on one face of the tube, parallel to a radial line.

Machining test was performed at a cutting speed of 150 m/min, at a depthof cut of 0.2 mm and a feed rate of 0.1 mm. The heavy interruptedcutting of workpiece took place by facing the cross section of the tubematerial. A “pass” was defined as machining of the tube cross sectionfrom outer diameter to inner diameter and tool performance was measuredby counting the number of passes before the tool edge was fractured dueto heavy interrupted nature of cutting. The cutting forces weremonitored in order to identify tool edge breakage.

The performance of Material 1A on average was 76 passes whereas Material1B performed about 25% more number of passes, average tool life was 101passes.

Example 2

A sub-stoichiometric titanium carbonitride powder(Ti(C_(0.5)N_(0.5))_(0.8) of average particle size of 1.4 micron wasmixed with Al powder, average particle size of 5 micron, using tubularmixer. The mass ratio between Ti(C_(0.5)N_(0.5))_(0.8) and Al was 90:10.The powder mixture was pressed into a titanium cup to form a greencompact and heated to 1025° C. under vacuum for 30 minutes and thencrushed and pulverized. The powder mixture was then attrition milled for4 hours.

A CBN powder mixture, containing about 30 wt % CBN with average particlesize of 0.7 micron and remaining CBN with average particle size of 1.4micron, was added into the slurry to obtain overall 55 volume percentCBN. The CBN containing slurry was milled and mixed for an hour usingattrition milling. The slurry was dried under vacuum and formed into agreen compact and was sintered at 55 kbar (5.5 GPa) and about 1300° C.to produce a CBN compact.

Comparative Example 2 Material 2A:

A sub-stoichiometric titanium carbonitride powder,(Ti(C_(0.5)N_(0.5))_(0.8) of average particle size of 1.4 micron wasmixed with Al powder, average particle size of 5 micron, using tubularmixer. The mass ratio between Ti(C_(0.5)N_(0.5))_(0.8) and Al was 90:10.The powder mixture was pressed into a titanium cup to form a greencompact and heated to 1025° C. under vacuum for 30 minutes and thencrushed and pulverized. The powder mixture was then attrition milled for4 hours and 0.7 micron average particle size of CBN was added andattrition milled in hexane for an hour. The amount of CBN was added insuch a way that the total volume percentage of CBN in the mixture wasabout 55 percent. The slurry was dried under vacuum and formed into agreen compact and was sintered at 55 kbar (5.5 GPa) and about 1300° C.to produce a CBN compact.

This compact and the compact produced in Example 2 (hereinafter referredto as Material 2B) were analysed and compared in a machining test.

A sample piece from each material was analysed using image analysis asdescribed in Comparative Example 1. The results are summarised in Table2. Material 2B had a significantly broader CBN grain size range, (havinga distribution spread of 1.254 micron), than Material 2A.

TABLE 2 Summary of CBN grain size analysis results for Materials 2A and2B Material 2A Material 2B d10 0.285 0.57 d90 0.882 1.824 Distributionspread 0.597 1.254 (d90 − d10)

The sintered compacts were both cut using wire EDM and ground to formcutting inserts with standard ISO insert geometries as SNMN090308 with200 micron chamfer width and 20 degrees angle and a hedge hone of 15 to20 micron.

SAE 4340 hardened steel of 52HRC was machined using cutting speeds of150 m/min with a feed rate of 0.15 mm/rev and depth of cut of 0.2 mm.The workpiece material was a cylindrical shape, with outside diameter of110 mm and inside diameter of 55 mm. It also contained 6 holes with 10mm diameter at equal distance between outside and inside diameter andequal distance between the holes. Machining operation was a face turningoperation where cutting speed was kept constant across the diameter ofthe workpiece. The machining operation was alternating continuous andinterrupted cutting where the cutting tool edge pass through the holesand continuous part of the workpiece material.

The cutting test was continued until the cutting edge failed by edgefracture or edge chipping and number of facing cuts (one facing cut isequal to total distance cutting from outside diameter to inside diameterof the workpiece) were counted as an indication of cutting toolperformance. None of the tested tools failed as a result of excessiveflank wear.

Material 2A and Material 2B cutting performances were evaluated usingthe machining test as described above at a cutting speed of 150 m/min.The performance of Material 2A was 19 facing cuts whereas Material 2Bsurprisingly lasted for an average of 28 facing cuts. The achievedimprovement with Material 2B corresponds to about 50% improvement intool performance in relation to Material 2A. Material 2B with a bi-modalCBN grain size significantly improved tool life in cutting operationwhich involved severe interrupted cutting and continuous cutting byimproving chipping or fracture resistance of the cutting tool.

Example 3

A sub-stochiometric titanium carbonitride, TiN_(0.7) of average particlesize of 1.4 micron was mixed with Al powder, average particle size of 5micron, using tubular mixer. The mass ratio between TiN_(0.7) and Al was90:10. The powder mixture was pressed into a titanium cup to form agreen compact and heated to 1025° C. under vacuum for 30 minutes andthen crushed and pulverized.

The powder mixture was then attrition milled for 4 hours. A CBN powdermixture, containing about 30 wt % CBN with average particle size of 0.7micron and remaining CBN with average particle size of 2 micron, wasadded into the slurry at a certain amount to obtain overall 60 volumepercent CBN. The CBN added mixture was attrition milled in hexane anhour. The slurry was dried under vacuum and formed into a green compactand was sintered at 55 kbar (5.5 GPa) and at around 1300° C. to producea CBN compact.

Comparative Example 3 Material 3A:

A sub-stoichiometric titanium nitride, TiN_(0.7) of average particlesize of 1.4 micron was mixed with Al powder, average particle size of 5micron, using tubular mixer. The mass ratio between TiN_(0.7) and Al was90:10. The powder mixture was pressed into a titanium cup to form agreen compact and heated to 1025° C. under vacuum for 30 minutes andthen crushed and pulverized. The powder mixture was then attritionmilled for 4 hours and 0.7 micron average particle size of CBN was addedand attrition milled in hexane an hour. The amount of CBN was added insuch a way that the total volume percentage of calculated CBN in themixture was about 60 percent. The slurry was dried under vacuum andformed into a green compact and was sintered at 55 kbar (5.5 GPa) and ataround 1300° C. to produce a CBN compact.

This compact and the compact produced in Example 3 (hereinafter referredto as Material 3B) were analysed and compared in a machining test.

A sample piece from each material was analysed using image analysis asper the previous examples. The results are summarised in Table 3.Material 3B had a significantly broader CBN grain size range (having adistribution spread of 1.444 micron), than Material 3A.

TABLE 3 Summary of CBN grain size analysis results for Materials 3A and3B Material 3A Material 3B d10 0.253 0.876 d90 0.796 2.32 Distributionspread 0.543 1.444 (d90 − d10)

The sintered compacts were both cut using wire EDM and ground to formcutting inserts with standard ISO insert geometries as SNMN090308 with200 micron chamfer width and 20 degrees angle and a hedge hone of 15 to20 micron.

A powder metallurgy alloy of high Cr steel material was used forcontinuous cutting experiments. The workpiece material (K190) containsabout 30 vol % abrasive carbide phases in a soft ferrite matrix.Therefore, this material is very abrasive and leads to appreciableamount of flank wear.

The test bar was machined using cutting speeds of 150 m/min with a feedrate of 0.1 mm/rev and depth of cut of 0.2 mm. The workpiece is dividedinto sections of 80 mm in length of round test bars machining testinvolved continuous cutting of round bar of 80 mm in length. The cuttingtest was continued until the cutting edge reached to approximately 300micron maximum flank wear (Vb max). The total cutting distance wasmeasured and normalised to corresponding 300 micron maximum flank wear.All of the tools were failed by excessive flank wear.

Material 3A and Material 3B cutting performances were evaluated usingthe machining test as described above at a cutting speed of 150 m/min.The performance of Material 3A was 992 m cutting distance whereasMaterial 3B performed a cutting distance of 1473 m. The achievedimprovement with Material 3B corresponds to about 48% improvement intool performance in relation to Material 3A. Material 3B with a bi-modalCBN grain size significantly improved tool life in cutting operationwhich involved severe abrasion wear by improving the materials abrasivewear resistance.

1-16. (canceled)
 17. A CBN compact which comprises CBN and a matrixphase, wherein the CBN grain size volume frequency distribution has adistribution spread expressed as d90-d10 of 1 micron or greater, and thed90 maximum value is 5 micron or less.
 18. A CBN compact according toclaim 17, wherein the d90 maximum value is 3.5 micron or less.
 19. A CBNcompact according to claim 18, wherein the d90 maximum value is 2.5micron or less.
 20. A CBN compact according to claim 17, wherein thematrix phase comprises a secondary hard phase including a compoundcontaining a nitride or carbonitride of a Group 4, 5 or 6 transitionmetal or a mixture or solid solution thereof.
 21. A CBN compactaccording to claim 20, wherein the Group 4, 5 or 6 transition metal istitanium.
 22. A CBN compact according to claim 20, wherein the matrixphase further comprises a binder phase consisting of aluminum andoptionally one or more of other elements chosen from silicon, iron,nickel, cobalt, titanium, tungsten, niobium and molybdenum, which one ormore other elements is alloyed, compounded or formed in solid solutionwith the aluminum.
 23. A tool insert comprising a CBN compact accordingto claim
 17. 24-27. (canceled)